Three-dimensional printing control

ABSTRACT

A three-dimensional (3D) object production system and methods for 3D printing reactive components to form a thermoset product. The disclosure relates to Use of a 3D printer having a controller comprising one or more processors to print a 3D object. The disclosure also provides a 3D object production system and methods for 3D printing comprising adjusting one or more parameters of an at least one actuator to produce a 3D object based on a reaction rate between reactive components.

The disclosure herein relates to three-dimensional printing controlmethods and processes, and further to systems, devices, and apparatusfor performing and implementing such methods and processes. Thedisclosure also relates to using a controller to control a viscosity, adegree of polymerization, and an aspect ratio of a thermoset product andprint a 3D object based on control of the viscosity, degree ofpolymerization, and aspect ratio.

BACKGROUND

Fused filament fabrication (FFF), also referred to in the art asthermoplastic extrusion, plastic jet printing (PJP), fused filamentmethod (FFM), or fusion deposition modeling, is an additivemanufacturing process wherein a material is extruded in successivelayers onto a platform to form a 3-dimensional product. Typically, FFFuses a melted thermoplastic material that is extruded onto alower-temperature platform. Three-dimensional printing (3D printing)often uses support structures which are easily dissolved or removed fromthe part after it is finished.

Disadvantages of existing FFF technology using thermoplastics includesingle material property printing, limited print-direction strength,limited durability, and limited softness. Thermosetting materials havegenerally not been used in FFF because prior to cure, the monomers arelow viscosity liquids, and upon deposition, the curing liquid flows orbreaks into droplets, resulting in finished parts of low quality andundesirably low resolution. In practice, attempts to print withthermoset materials has required addition of fillers (such as inorganicpowders or polymers) to induce thixotropic behavior in the resin beforeit is fully cured. These solutions affect the final properties of theprinted part. Other problems include poor resolution control in theprinted part and frequent clogging of mixing systems.

SUMMARY

It may be described that the exemplary systems and methods describedherein may control, or adjust, various part properties by controlling,or modifying one or more of a plurality of reactive components toprovide a thermoset product for use in 3D printing. For example, aproportion of flow from isocyanate sources based on isocyanateattributes may be used to control part flexibility, color, opticalrefractive index, etc. (for instance, more specifically, smallermolecular weight (Mw) may provide, or give, more rigid materials, higherMw give more flexible materials).

Further, for example, a proportion of flow from polyol sources based onpolyol attributes may be used to control part flexibility, color,optical refractive index, etc. (for instance, more specifically, smallermolecular weight may give, or provide, more rigid materials, higher Mwgive more flexible materials). Still further, for example, a proportionof flow from a gas-generation source, such as a blowing agent orreactive species that generates gas may be used to control part porosityor density (e.g., to create a controlled “foam”).

It may be described that the exemplary systems and methods may includeor utilize various extruded thermoset printing apparatus to monitor/fixvarious issues, control various parameters, or control environmentalconditions when generating or creating 3D objects. For example, theextruded thermoset printing apparatus may be configured to detectobstruction in the print flow tubing/nozzle by detecting torque on themotors (e.g., using torque upper limits to detect viscosities that areout of the operating range), monitoring the flow within the tubing,and/or pressure within the printing apparatus. Detection of anobstruction may trigger change or cleaning of the mixing system.Further, for example, a mixing quality may be detected, or determined(e.g., using metering pumps to ensure the right ratios of materials arebeing mixed together or chemical analysis), as material exits theprinthead, such as by a color detection or chemical detection, which maythen be used to delay deposition of material on part, purge materialinto a purge area until mixing is achieved, and/or warn a user. Stillfurther, for example, the pressure of each resin may be detected, andmotor displacement may be controlled as necessary to achieve desiredmaterial flow rate or stop flow. In other words, the exemplary systemsand methods may use pressure feedback to monitor actual volume flow tocompare against calculated volume flow. Still further, for example, flowof the various reactive components or resultant thermoset product may bemonitored. More specifically, flow feedback may be used to monitoractual volume flow to compare against calculated volume flow. Stillfurther, for example, weight of the 3D object be printed, or created,may be monitored, and used in various control processes. In other words,the printing apparatus may be configured to detect the weight of theprint and that the amount pumping is keeping up with the program desiredamount. Further, the amount of material exiting onto the platform may beverified to match the theoretical amount such that, e.g., corrections oradjustments can be made. Still further, for example, pressure may beadapted for container diameter. More specifically, a sensing system maybe used to compensate for the gradient of pressure needed acrossdifferent sized vessels during printing of the reactive materials, andanother measuring device would ensure consistent flow.

And still further, for example, the printing apparatus may include a tipwiping mechanism to clean tip to prevent glob formation and drag. Morespecifically, the tip wipe may have a ‘clean’ area to wipe the tip ofthe nozzle clean. Since the polyurethane will cure and harden, theremust be a ‘clean’ area to wipe. Further, the tip wipe may bereplaceable.

Yet still further, the printing apparatus may provide, or include, ahumidity controlled cabinet to control moisture that leads to partquality. The humidity controlled cabinet may have an internal orexternal active system to remove moisture. Further, the controlledcabinet may have at least two functions: remove the moisture to helpbuild parts and create a narrower band wide of moisture (which may allowless testing of variables).

Still further, for example, the printing apparatus may provide, orinclude, a purge container (e.g., a bucket) to put purged material.Material may be purged at the beginning of a part or inside a part tokeep the nozzle from locking up with curing materials.

Still further, for example, the printing apparatus may be able tocontrol cabinet temperature. For instance, the cabinet may have sidesand ceiling to contain the heated air. The temperature of the internalcabinet will help define the curing time of polyurethane. As the cabinettemperature raises, the polyurethane viscosity may increase, and thecure time may decrease. Also, raising the internal temperature, theenvironment temperature would be removed or reduced.

It may also be described that the exemplary systems and methods maycontrol, or adjust, various print conditions to provide desired geometryand resulting part-filling of the strand placed on the part. Forexample, time per layer, flow rate through nozzle, viscosity at nozzle,and cure acceleration may be adjusted, or modified. Further, thetemperature of the resin may affect viscosity change out of the nozzleand a faster reaction speed of the material. The conditions from thetiming of the viscosity and reaction rate of the material may create aprofile of the material which translates to the resulting physical andmechanical properties. Timing of the viscosity and reaction rate canaffects the space-filling properties of the material. Properspace-filling can improve mechanical properties and control of theviscosity and flow rate can allow for faster printing without losingpart resolution. Still further, for example, the increased temperatureof the platform may create a lowering of viscosity and a quickerreaction speed of the material closest to the platform and may create adifferent viscosity and reactivity for the exiting material, especiallyfor the base layers. Still further, for example, the temperature of thebuild volume may create a quicker reaction speed and start to speed theoverall cure of the finished part. Still further, for example,temperature at the extrusion nozzle may also be able to alter the cureas it is deposited and resulting strand geometry, e.g., for quickreactive cure adjustments. And still further, for example, the humidityof the printing chambers may be used to control, or affect, theformation of bubble defects in a part.

It may also be described that the exemplary systems and methods maycontrol, or adjust, various bead shapes of the thermoset product usingnozzle diameter, height of the nozzle from the 3D object being printed,and nozzle tip shape. In general, the smaller the tip (ID) size, thebetter the part resolution. More specifically, the tip (ID) for the mostpart may define the maximum/minimum volume rate. In general, if the flowvolume is smaller than the tip (ID) the out flow may “walk” between theedges of the tip (ID). If the flow volume creates a cross-section largerthan the tip (OD), the material may flow up around the tip, creating anon-flat top surface. Further, the part definition may be defined by thesupport angle and the resolution of the part.

Still further, bead formation may be flattened if desired. In general,the exemplary systems and methods may affect the ability to shape thetop of the bead.

It may also be described that the exemplary systems and methods maycontrol, or adjust, various tool path controls. For example, thetranslation path for each layer may control the flow and resolution ofthe printed part. At the end of segment/contour, the tip may be moved tothe next segment/contour, and the exemplary systems and methods may moveto the next position by changed flowing (e.g., reduced or stopped flow).The creation of the toolpath should be such that the start of the nextsegment/contour should be as close as possible. Further, for example,the exemplary systems and methods may control whether to use a parallelor perpendicular pattern to controls the resulting strength isotropy ofthe part. Further, stress-strain results may be used to modify thegenerated toolpath to return the “strongest” or “more flexible” toolpathbased on the collected data from the strength tests. Still further, forexample, the time per layer may control time to harden previous layer.There will be a “minimum layer time,” which may be defined as theminimum amount of time it takes to partially cure or gel a layer ofpolyurethane of given volume. If the next layer is printed before thisminimum time, then the previous layer may deform by the weight of thecurrent layer, and the exemplary systems and methods may adjust headspeed in view thereof. And still further, the stoichiometry and/or ratioof reactive components, or specie, may further be used to control partquality. Yet still further, the exemplary systems and methods may beused to control the seams of the 3D object (“seam control”). Morespecifically, the seams may be reduced by overlapping or hiding theseams on the inside of the 3D object by using different Z, or height,levels at start and stop of a layer or path. Further, the start/end ofthe toolpath may be a given issue, and the start/end flow may be equalto the constant flow cross-section to, e.g., potentially avoid flaws.The start/end segment can overlap but there may be a change in thevolume. A potential seam flaw can be reduced hiding part or all of thestart/end segments inside the part. If the seam is internal, then thetoolpath may avoid this volume when filling the part, and the seamsegment can be moved in Z, or height dimension, to reduce the fillvolume (e.g., start lower in z, raise to layer height, then reduce thevolume flow over the end segment).

Still further, for example, the exemplary systems and methods mayinclude, or provide, automatic nozzle cleaning to allow cleaning betweenlayers and/or to clean off the buildup on the tip. The automaticcleaning can be timed or would be controlled with smart technology(e.g., recognized by a sensor). Thus, any collected material on the tipmay be removed before it becomes fully or near cured. In at least oneembodiment, the tip wipe could be made of a material that polyurethanedoes not stick to. (e.g., Silicone).

Still further, for example, the exemplary systems and methods mayinclude, or provide, speed control including acceleration. Morespecifically, the controller may have independent control of all axes(X,Y,Z) and may also have control of head volume flow. The control ofthe volume flow of the resin/polyethene may not be the same as the X,Y,Zaxes, and thus, the controller may start the resin/pu flow before/afterthe start of the X,Y,Z axes movement. Also, theacceleration/de-acceleration may be different for each or all of theaxes and may be controlled to create a desired consistent volume flow

And still further, for example, the exemplary systems and methods mayinclude, or provide corner speed control to, e.g., control thedefinition of the corner areas. To create a higher speed print, longersegments (e.g., longer, straighter segments) may have a higher printspeed than corners. The controller may control all the axes to create asmooth and consistent volume flow through the corner.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of an exemplary 3D object production system.

FIG. 2 is a block diagram of extruded thermoset printing apparatus ofthe system of FIG. 1.

FIG. 3 is a block diagram of an exemplary 3D object production system.

FIG. 4 is a printed 3D object having two different thermoset components.

FIG. 5 is a block diagram of an exemplary 3D object production system.

FIG. 6 is an extruder capable of combining up to 8 reactive components.

FIG. 7 is an extruder and extrusion nozzle.

FIG. 8 shows a cross section of three beads.

FIG. 9 is a pyramid shaped 3D printed object.

FIG. 10 is a computer diagram of a flattened donut.

FIG. 11 is a 3D printed flattened donut.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

In the following detailed description of illustrative embodiments,reference is made to the accompanying figures of the drawing which forma part hereof, and in which are shown, by way of illustration, specificembodiments which may be practiced. It is to be understood that otherembodiments may be utilized and structural changes may be made withoutdeparting from (e.g., still falling within) the scope of the disclosurepresented hereby.

Various examples and embodiments of the inventive subject matterdisclosed here are possible and will be apparent to a person of ordinaryskill in the art, given the benefit of this disclosure. In thisdisclosure reference to “some embodiments,” “certain embodiments,”“certain exemplary embodiments” and similar phrases each means thatthose embodiments are non-limiting examples of the inventive subjectmatter, and there may be alternative embodiments which are not excluded.

The articles “a,” “an,” and “the” are used herein to refer to one ormore than one (i.e., to at least one) of the grammatical object of thearticle. By way of example, “an element” means one element or more thanone element.

As used herein, the term “about” means±10% of the noted value. By way ofexample only, a composition comprising “about 30 wt. %” of a compoundcould include from 27 wt. % of the compound up to and including 33 wt. %of the compound.

The word “comprising” is used in a manner consistent with its open-endedmeaning, that is, to mean that a given product or process can optionallyalso have additional features or elements beyond those expresslydescribed. It is understood that wherever embodiments are described withthe language “comprising,” otherwise analogous embodiments described interms of “consisting of” and/or “consisting essentially of” are alsocontemplated and within the scope of this disclosure.

As used herein, the terms “thermoset,” “thermoset product,” and“thermoset material” are used interchangeably and refer to the reactionproduct of at least two chemicals which form a covalently bondedcrosslinked or polymeric network. In contrast to thermoplastics, athermoset product described herein may irreversibly solidify or set.

As used herein, the term “elastomer” means a polymer (e.g., apolyurethane) that is deformable when stress is applied, but retains itsoriginal shape after the stress is removed.

As used herein, the term “layer” refers to a strand of thermoset productthat has been extruded from an extrusion nozzle and deposited on, forinstance, a substrate.

A layer is initially a partially reacted thermoset product, and cures tobecome a completely reacted thermoset product.

As used herein, the term “partially reacted thermoset product” refers toa covalently bonded crosslinked or polymeric network that is stillreactive. For example, it still has hydroxyl, amine, and/or isocyanatefunctionality that gives a measureable hydroxyl number, NH number, orNCO number in a titration. In another embodiment, a partially reactedthermoset product is a thermoset product that has a viscosity below3,000,000 cp. In one embodiment, a partially reacted thermoset productis a thermoset product that has a molecular weight of no greater than100,000 g/mol.

As used herein, the term “completely reacted thermoset product” means acovalently bonded crosslinked or polymeric network that has nomeasurable reactive groups (e.g., hydroxyl, amine, or isocyanatefunctionality). In another embodiment, a completely reacted thermosetproduct is one that is a solid and has no measurable viscosity.

As used herein, the term “environmental parameter” means one or more oftemperature, moisture level, and humidity.

In certain embodiments, the three-dimensional (3D) object productionsystem or the three-dimensional (3D) object production method includes acontroller comprising one or more processors. In certain embodiments,the three-dimensional (3D) object production system or thethree-dimensional (3D) object production method can be operably coupledto an extruded thermoset printing apparatus. In certain embodiments, thethe three-dimensional (3D) object production system or thethree-dimensional (3D) object production method comprises at least oneactuator operably coupled to the extrusion nozzle to move the extrusionnozzle when delivering thermoset product to form the 3D object.

In certain embodiments, the controller comprising one or more processorscan provide instructions to the extruded thermoset printing apparatus.These instructions can modify the method for printing a 3D object. Incertain embodiments, these instructions instruct at least one actuatoroperably coupled to the extrusion nozzle to move the extrusion nozzlewhen delivering thermoset product to form the 3D object.

In certain embodiments, the controller can adjust one or more parametersof the at least one actuator to produce the 3D object based on areaction rate between a first reactive component and a second reactivecomponent to provide the thermoset product. In certain embodiments, thecontroller can adjust one or more parameters of the at least oneactuator to produce the 3D object based on a reaction rate between afirst reactive component, a second reactive component, and a thirdreactive component to provide the thermoset product. In certainembodiments, the controller can adjust one or more parameters of the atleast one actuator to produce the 3D object based on a reaction ratebetween a first reactive component, a second reactive component, and atleast one additional reactive component (e.g., three, four, five, six,seven, eight, nine, or ten total reactive components) to provide thethermoset product.

Applicant has surprisingly discovered that adjusting one or moreparameters of the at least one actuator to produce the 3D object basedon a reaction rate between the reactive components can provide anunexpectedly superior 3D printed object as compared to methods in theart. In certain embodiments, the one or more parameters can comprise atleast one of a time per layer of thermoset product, a flow rate of thethermoset product through the extrusion nozzle, a viscosity of thethermoset product through the extrusion nozzle, a cure acceleration ofthe thermoset product, a layer translation path, a layer pattern, a seamstructure, movement speed, and corner speed.

In certain embodiments, a time per layer of the thermoset product can beadjusted to optimize the time between layers extruded by the extrusionnozzle. Depending on the properties of the reactive components and thegeometry of the desired final 3D product, the time per layer adjustmentcan vary. As used herein, the term “time per layer of thermoset product”means the minimum amount of time which should elapse before a next layercan be deposited on top of it.

In certain embodiments, the minimum time per layer of thermoset productcan be from about 10 seconds to several hours. In certain embodiments,the time per layer of thermoset product can be from about 30 seconds toabout 30 minutes. In certain embodiments, the time per layer ofthermoset product can be from about 60 seconds to about 20 minutes. Incertain embodiments, the time per layer of thermoset product can beabout 10 seconds, about 20 seconds, about 30 seconds, about 40 seconds,about 50 seconds, about 60 seconds, about 2 minutes, about 3 minutes,about 4 minutes, about 5 minutes, about 6 minutes, about 7 minutes,about 8 minutes, about 9 minutes, about 10 minutes, about 15 minutes,about 20 minutes, about 25 minutes, about 30 minutes, about 35 minutes,about 40 minutes, 50 minutes, 1 hour, 1.5 hours, 2 hours, or any rangesbetween the specified values. If an insufficient amount of time haselapsed between depositing a layer and subsequently depositing anotherlayer, when the next layer is deposited, it can melt or flow into theprior layer. In certain embodiments, a layer has height x, and when thenext layer is deposited, the height of the part can be 2×. If aninsufficient amount of time has elapsed, after the next layer isdeposited, the height can be less than 2×. In certain embodiments, ifthe height is within about 5% of 2×, the minimum time can be said tohave elapsed

In certain embodiments, a flow rate of the thermoset product through theextrusion nozzle can be adjusted to optimize the flow rate through theextrusion nozzle. Depending on the properties of the reactive componentsand the geometry of the desired final 3D product, the flow rateadjustment can vary. As used herein, the term “flow rate through theextrusion nozzle” means a volumetric flow rate, or a volume of materialin mm³ that is pushed through the nozzle in a second. The rate can varydepending on the tip diameter. In certain embodiments, the minimum ratecan be set by the strength of the pump on the printer. In certainembodiments, the flow rate can controlled by the setting the pumpdisplacement.

In certain embodiments, the flow rate through the extrusion nozzle canbe from about 0.01 mm³/s to about 1 mm³/s. In certain embodiments, theflow rate can be from about 0.05 mm³/s to about 0.75 mm³/s. In certainembodiments, the flow rate can be from about 0.1 mm³/s to about 0.5mm³/s. In certain embodiments, the flow rate can be about 0.01 mm³/s,about 0.02 mm³/s, about 0.03 mm³/s, about 0.04 mm³/s, about 0.05 mm³/s,about 0.06 mm³/s, about 0.07 mm³/s, about 0.08 mm³/s, about 0.09 mm³/s,about 0.1 mm³/s, about 0.15 mm³/s, about 0.2 mm³/s, about 0.25 mm³/s,about 0.3 mm³/s, about 0.35 mm³/s, about 0.4 mm³/s, about 0.45 mm³/s,about 0.5 mm³/s, about 0.55 mm³/s, about 0.6 mm³/s, about 0.65 mm³/s,about 0.7 mm³/s, about 0.75 mm³/s, about 0.8 mm³/s, about 0.85 mm³/s,about 0.9 mm³/s, about 0.95 mm³/s, about 1 mm³/s, or any ranges betweenthe specified values. In certain embodiments, the flow rate of thematerial, combined with the volume of the mixing chamber, can set theextent of reaction of the material at the time that it leaves thenozzle. For example, if the printer is printing at 0.1 mm³/s and themixer has a volume of 2 mm³, then the reaction mixture can be, onaverage, about 20 seconds into its reaction. If the flow rate isdecreased to 0.01 mm³/s, then the reaction mixture can be, on average,about 200 seconds into its reaction.

In certain embodiments, a viscosity of the thermoset product through theextrusion nozzle can be adjusted to optimize the viscosity of thethermoset product product through the extrusion nozzle. Depending on theproperties of the reactive components and the geometry of the desiredfinal 3D product, the viscosity can vary. Viscosity increases as afunction of molecular weight of a polymer. Viscosity also increases as afunction of concentration of urethane and urea linkages in the material.Therefore, for a given A (isocyanate blend) and B (polyol blend), asthey react, the viscosity will increase. For example, for a given A andB, if a mixture leaves the extrusion nozzle at 200 seconds, it can havea higher extent of reaction, higher density of urethane/urea groups, andhigher molecular weight than if it leaves the extrusion nozzle at 20seconds. In certain embodiments, as the time from mixing of reactivecomponents to the time a mixture leaves an extrusion nozzle increases,the viscosity can increase.

In certain embodiments, a material with a higher extent of reaction cangive a bead with a different aspect ratio (cross-sectional width overheight) than one with a lower extent of reaction. In certainembodiments, the aspect ratio can be from about 1 to about 10. Incertain embodiments, the aspect ratio can be from about 1 to about 5. Incertain embodiments, the aspect ratio about 1, about 1.5, about 2, about2.5, about 3, about 3.5, about 4, about 4.5, about 5, about 6, about 7,about 8, about 9, about 10, or any ranges between the specified values.In certain embodiments, the aspect ratio can be inversely proportionalto the viscosity. For example, an aspect ratio of 1 will be for a higherviscosity bead than an aspect ratio of 5, which is for a lower viscositybead.

Applicant has surprisingly found that controlling aspect ratio of thebead can provide for printing optimization and provide for a printed 3Dobject with desirable object resolution. In certain embodiments, theaspect ratio can be used to set the space filling attributes of amaterial. In certain embodiments, the aspect ratio is related to theextent of polymerization of a material and the viscosity of a material.For example, if an aspect ratio is 5, then the layer height is shorter,but the translation path of the printhead can travel with a greaterdistance between adjacent beads. Comparatively, if an aspect ratio is 1,then the translation path provides that adjacent beads be placed closerto produce a solid part. In certain embodiments, the flow rate throughthe printhead, which sets its viscosity and therefore bead aspect ratio,can be used to set resolution, as well as overall printing speed. Atslower flow rates and low aspect ratios, the print resolution can be thebead width. At higher flow rates, the high aspect ratio allows a layerto be filled quickly with fewer adjacent beads. The resolution can bethe wider bead width associated with the lower viscosity.

In certain embodiments, a controller can analyze aspect ratio and printa 3D object based on the aspect ratio of a bead. For example, thecontroller can instruct the 3D printer to print with a low aspectratio/high viscosity bead for certain aspects of a 3D object and thenthe controller can instruct the 3D printer to print with a high aspectratio/low viscosity bead for other aspects of a 3D object. Thiscontrolling of aspect ratio can provide a 3D object with highresolution, e.g., on the edges of a 3D object, and then use increasedprinting speeds to space fill aspects of a 3D object.

In certain embodiments, a cure acceleration of the thermoset product canbe adjusted to optimize the cure acceleration of the thermoset product.Depending on the properties of the reactive components and the geometryof the desired final 3D product, the cure acceleration can vary. Incertain embodiments, a cure acceleration can be achieved by increasingthe extent of reaction at a given time. In certain embodiments, anaccelerant can be a catalyst or a formula with reactants designed withhigher reactivity.

In certain embodiments, a layer translation path can be adjusted tooptimize the layer translational path of the extruded thermoset product.Depending on the properties of the reactive component and the geometryof the desired final 3D product, the layer translational path can vary.As used herein the term “layer translation path” means the path that istraversed by the printhead while depositing material in the layer. Incertain embodiments, the path can be followed to deposit material in theareas that have been specified by the slicing application. In certainembodiments, the layer translational path can be chosen such that aminimum amount of time elapses before an adjacent bead is placed. Incertain embodiments, this minimum amount of time can be from about 1second to about 5 minutes. In certain embodiments, this minimum amountof time can be from about 5 seconds to about 1 minute. In certainembodiments, this minimum amount of time can be about 1 second, about 5seconds, about 10 seconds, about 15 seconds, about 20 seconds, about 25seconds, about 30 second, about 35 seconds, about 40 seconds, about 45seconds, about 50 seconds, about 60 second, about 90 seconds, about 2minutes, about 3 minutes, about 4 minutes, about 5 minutes, or anyranges between the specified values. If an insufficient amount of timehas elapsed, the beads can combine and form a bead with a differentaspect ratio than a single bead. In certain embodiments, the algorithmwhich constructs a translation path can control a layer translation pathsuch that a bead deformation does not occur when beads are placedadjacent to one another.

In certain embodiments, a layer pattern can be adjusted to optimize thelayer pattern of the extruded thermoset product. Depending on theproperties of the reactive component and the geometry of the desiredfinal 3D product, the layer pattern can vary. As used herein the term“layer pattern” means the pattern that is traversed by the printheadwhile depositing material in the layer. In certain embodiments, a layerpattern can be the systematic path that the printhead is directed tofill an area. In certain embodiments, a layer pattern can be to fill acircle with concentric circles from the outside in. In certainembodiments, a layer pattern can be a pattern where adjacent parallellines are placed. In certain embodiments, the layer pattern can bechosen such that a minimum amount of time elapses before an adjacentbead is placed. In certain embodiments, this minimum amount of time canbe from about 1 second to about 5 minutes. In certain embodiments, thisminimum amount of time can be from about 5 seconds to about 1 minute. Incertain embodiments, this minimum amount of time can be about 1 second,about 5 seconds, about 10 seconds, about 15 seconds, about 20 seconds,about 25 seconds, about 30 second, about 35 seconds, about 40 seconds,about 45 seconds, about 50 seconds, about 60 second, about 90 seconds,about 2 minutes, about 3 minutes, about 4 minutes, about 5 minutes, orany ranges between the specified values. If an insufficient amount oftime has elapsed, the beads can combine and form a bead with a differentaspect ratio than a single bead. In certain embodiments, the algorithmwhich constructs a fill pattern can control a layer pattern such that abead deformation does not occur when beads are placed adjacent to oneanother.

In certain embodiments, a seam structure can be adjusted to optimize theseam structure of the extruded thermoset product. Depending on theproperties of the reactive components and the geometry of the desiredfinal 3D product, the seam structure can vary. As used herein, the term“seam structure” means the vertical line formed when each layer beginsprinting at the same X, Y point.

In certain embodiments, a movement speed can be adjusted to optimize themovement speed of the extruded thermoset product and of the extrusionnozzle. Depending on the properties of the reactive components and thegeometry of the desired final 3D product, the movement speed can vary.As used herein, the term “movement speed” means the linear speedtraversed by a printhead. In certain embodiments, the movement speed canbe from about 1 mm/s to about 50 mm/s. In certain embodiments, themovement speed can be from about 2 mm/s to about 25 mm/s. In certainembodiments, the movement speed can be about 1 mm/s, about 2 mm/s, about3 mm/s, about 4 mm/s, about 5 mm/s, about 6 mm/s, about 7 mm/s, about 8mm/s, about 9 mm/s, about 10 mm/s, about 11 mm/s, about 12 mm/s, about13 mm/s, about 14 mm/s, about 15 mm/s, about 16 mm/s, about 17 mm/s,about 18 mm/s, about 19 mm/s, about 20 mm/s, about 21 mm/s, about 22mm/s, about 23 mm/s, about 24 mm/s, about 25 mm/s, or any ranges betweenthe specified values.

In certain embodiments, a corner speed can be adjusted to optimize thecorner speed of the extruded thermoset product and of the extrusionnozzle. Depending on the properties of the reactive components and thegeometry of the desired final 3D product, the corner speed can vary. Asused herein the term “corner speed” can mean a minimum turning radiusfor a given linear speed. As each curve in a 3D printed bead is made upfrom several linear segments this ability to change direction can beexpresses as a maximum angular velocity where;

${{maximum}\mspace{14mu}{angular}\mspace{14mu}{velocity}\mspace{14mu}\omega} = \frac{d\;\theta}{d\; t}$and  where  θ  is  the  corner  angle andmaximum  linear  velocity  v = ω r where  r  is  the  radius  of  the  corner

In certain embodiments, the controller can adjust one or both of theamount and flow rate of one or more of first, second, and third reactivecomponents to provide a thermoset product for the first area of the 3Dobject design to provide the physical property of the first area that isdifferent than the same physical property of the second area. In certainembodiments, the physical property can be one or more of flexibility,color, optical refractive index, hardness, porosity, and density.

In certain embodiments, the controller can be configured to execute orthe method further comprises adjusting one or both of an amount and aflow rate of a gas-generation source for use with one or more of afirst, second, and third reactive components.

In certain embodiments, the controller can be configured to execute orthe method further comprises controlling a distance between theextrusion nozzle and the 3D object. Applicant has surprisinglydiscovered that controlling a distance between the extrusion nozzle andthe 3D object can provide an unexpectedly superior 3D printed object ascompared to methods in the art.

In certain embodiments, the controller can be configured to detect anobstruction within the extruded thermoset printing apparatus. In certainembodiments, the controller can be configured to remove an obstructionwithin the extruded thermoset printing apparatus. During 3D printing,reactive components can obstruct, clog, block, or fill a part of theextruded thermoset printing apparatus. By using the controller to detectand remove an obstruction, a uniform and accurate 3D printed object canbe printed. In certain embodiments, the obstruction can be inside thethe extruded thermoset printing apparatus (e.g., on the inside of thenozzle). In certain embodiments, the obstruction can be on the exteriorof the extruded thermoset printing apparatus (e.g., on the outside ofthe nozzle or on the tip of the nozzle). In certain embodiments, theobstruction is removed automatically, e.g., by purging to a disposalcup. In certain embodiments, the obstruction is removed manually, e.g.,by manually wiping the nozzle.

Exemplary systems, apparatus, devices, methods, and processes shall bedescribed with reference to FIGS. 1-2. It will be apparent to oneskilled in the art that elements or processes from one embodiment may beused in combination with elements or processes of the other embodiments,and that the possible embodiments of such systems, apparatus, devices,methods, and processes using combinations of features set forth hereinis not limited to the specific embodiments shown in the figures and/ordescribed herein. Further, it will be recognized that the embodimentsdescribed herein may include many elements that are not necessarilyshown to scale. Still further, it will be recognized that timing of theprocesses and the size and shape of various elements herein may bemodified but still fall within the scope of the present disclosure,although certain timings, one or more shapes and/or sizes, or types ofelements, may be advantageous over others.

The exemplary 3D object production system 10 used to execute, orperform, the exemplary methods and/or processes described herein isfurther depicted diagrammatically in FIG. 1. As shown, the exemplarysystem 10 may include computing apparatus 12. The computing apparatus 12may be configured to receive input and transmit output to extrudedthermoset printing apparatus 100 such that, for example, the computingapparatus 12 may use, or work with, the extruded thermoset printingapparatus 100 to produce a 3D object.

Further, the computing apparatus 12 may include data storage 14. Datastorage 14 may allow for access to processing programs or routines 16and one or more other types of data 18 (e.g., 3D object designs,computer-aided design (CAD) files, sensor data, material properties,parameters, metrics, variables, etc.) that may be employed to perform,or carry out, exemplary methods and/or processes for use in performingcontrol of production of 3D objects and/or translation of 3D designsinto one or more printing processes to produce 3D objects. The computingapparatus 12 may be described as being operatively coupled to theextruded thermoset printing apparatus 100 to, e.g., transmit data to andfrom the extruded thermoset printing apparatus 100. For example, thecomputing apparatus 12 may be electrically coupled to the extrudedthermoset printing apparatus 100 using, e.g., analog electricalconnections, digital electrical connections, wireless connections,bus-based connections, etc.

The processing programs or routines 16 may include programs or routinesfor performing computational mathematics, a slicing application, CADprocesses, 3D design translation algorithms and processes, spatialalgorithms, process automation algorithms, matrix mathematics,standardization algorithms, comparison algorithms, feedback controlloops, or any other processing required to implement one or moreexemplary methods and/or processes described herein. Data 18 mayinclude, for example, 3D object design data, 3D object information,parameters, 3D printing parameters, material properties, sensor data,variables, results from one or more processing programs or routinesemployed according to the disclosure herein, or any other data that maybe necessary for carrying out the one and/or more processes or methodsdescribed herein.

In one or more embodiments, the system 10 may be implemented using oneor more computer programs executed on programmable computers, such ascomputers that include, for example, processing capabilities, datastorage (e.g., volatile or non-volatile memory and/or storage elements),input devices, and output devices. Program code and/or logic describedherein may be applied to input data to perform functionality describedherein and generate desired output information. The output informationmay be applied as input to one or more other devices and/or methods asdescribed herein or as would be applied in a known fashion.

The programs used to implement the methods and/or processes describedherein may be provided using any programmable language, or code, e.g., ahigh-level procedural and/or object orientated programming language orcode that is suitable for communicating with a computer system. Any suchprograms may, for example, be stored on any suitable device, e.g., astorage media, that is readable by a general or special purpose programrunning on a computer system (e.g., including processing apparatus) forconfiguring and operating the computer system when the suitable deviceis read for performing the procedures described herein. In other words,at least in one embodiment, the system 10 may be implemented using acomputer readable storage medium, configured with a computer program,where the storage medium so configured causes the computer to operate ina specific and predefined manner to perform functions described herein.Further, in at least one embodiment, the system 10 may be described asbeing implemented by logic (e.g., object code) encoded in one or morenon-transitory media that includes code for execution and, when executedby a processor, is operable to perform operations such as the methods,processes, and/or functionality described herein.

The computing apparatus 12 may be, for example, any fixed or mobilecomputer system (e.g., a controller, a microcontroller, a personalcomputer, minicomputer, etc.). The exact configuration of the computingapparatus 12 is not limiting, and essentially any device capable ofproviding suitable computing capabilities and control capabilities maybe used as described herein, a digital file may be any medium (e.g.,volatile or non-volatile memory, a CD-ROM, magnetic recordable tape,etc.) containing digital bits (e.g., encoded in binary, etc.) that maybe readable and/or writeable by computing apparatus 12 described herein.Also, as described herein, a file in user-readable format may be anyrepresentation of data (e.g., ASCII text, binary numbers, hexadecimalnumbers, decimal numbers, graphically, etc.) presentable on any medium(e.g., paper, a display, etc.) readable and/or understandable by anoperator.

In view of the above, it will be readily apparent that the functionalityas described in one or more embodiments according to the presentdisclosure may be implemented in any manner as would be known to oneskilled in the art. As such, the computer language, the computer system,or any other software/hardware which is to be used to implement theprocesses described herein shall not be limiting on the scope of thesystems, processes or programs (e.g., the functionality provided by suchsystems, processes or programs) described herein.

The methods and/or logic described in this disclosure, including thoseattributed to the systems, or various constituent components, may beimplemented, at least in part, in hardware, software, firmware, or anycombination thereof. For example, various aspects of the techniques maybe implemented within one or more processors, including one or moremicroprocessors, DSPs, ASICs, FPGAs, or any other equivalent integratedor discrete logic circuitry, as well as any combinations of suchcomponents, or other devices. The term “processor” or “processingcircuitry” may generally refer to any of the foregoing logic circuitry,alone or in combination with other logic circuitry, or any otherequivalent circuitry.

Such hardware, software, and/or firmware may be implemented within thesame device or within separate devices to support the various operationsand functions described in this disclosure. In addition, any of thedescribed components may be implemented together or separately asdiscrete but interoperable logic devices. Depiction of differentfeatures, e.g., using block diagrams, etc., is intended to highlightdifferent functional aspects and does not necessarily imply that suchfeatures must be realized by separate hardware or software components.Rather, functionality may be performed by separate hardware or softwarecomponents, or integrated within common or separate hardware or softwarecomponents.

When implemented in software, the functionality ascribed to the systems,devices and methods described in this disclosure may be embodied asinstructions and/or logic on a computer-readable medium such as RAM,ROM, NVRAM, EEPROM, FLASH memory, magnetic data storage media, opticaldata storage media, or the like. The instructions and/or logic may beexecuted by one or more processors to support one or more aspects of thefunctionality described in this disclosure.

The extruded thermoset printing apparatus 100 may include any one ormore devices, mechanisms, and structures so as to be capable ofperforming the 3D object generation or printing as described herein.Generally, as shown in FIG. 2, the extruded thermoset printing apparatus100 may include at least a first reactant chamber for holding, orcontain, a first reactant and one or more additional reactant chambers,or nth reactant chamber, for holding, or contain, additional or nthreactants. The reacting chambers may be operably coupled to a mixingchambers such that the reactants may be mixed to produce, or provide,thermoset product as described herein. The mixing chamber may beoperably coupled to the extrusion nozzle, which can deliver thethermoset product to a production chamber where the 3D object is beingprinted or formed.

Each of the portions or items of the system 100, some of which aredepicted in FIG. 2, may have corresponding monitoring apparatus operablycoupled thereto. For example, the apparatus 100 may include firstreactant chamber monitoring apparatus operably coupled to the firstreactant chamber to monitor one or more parameters and/or variablesrelated thereto, and nth reactant chamber monitoring apparatus operablycoupled to the nth reactant chamber to monitor one or more parametersand/or variables related thereto. Further, the apparatus 100 may includemixing chamber monitoring apparatus, extrusion nozzle monitoringapparatus, and production monitoring apparatus operably coupled to themixing chamber, extrusion nozzle, and production chamber, respectively,to monitor one or more parameters and/or variables related thereto.

Each of the portions or items of the system 100, some of which aredepicted in FIG. 2, may have corresponding control apparatus operablycoupled thereto. For example, the apparatus 100 may include firstreactant chamber control apparatus operably coupled to the firstreactant chamber to control, modify, or adjust one or more settings,parameters, and/or processes related thereto, and nth reactant chambercontrol apparatus operably coupled to the nth reactant chamber tocontrol one or more settings, parameters, and/or processes relatedthereto. Further, the apparatus 100 may include mixing chamber controlapparatus, extrusion nozzle control apparatus, and production controlapparatus operably coupled to the mixing chamber, extrusion nozzle, andproduction chamber, respectively, to control one or more settings,parameters, and/or processes related thereto.

FIG. 3 is a block diagram of an exemplary 3D object production system.In FIG. 3, the slicing application software sends an object descriptionto a controller. The controller sends control instructions to a 3Dprinter to print a 3D object. The 3D printer sends feedback to thecontroller, which then sends feedback to the slicing application.

FIG. 4 is a printed 3D object having two different thermoset components.The 3D object has the shape of a star. The interior darker coloredportion of the star is composed of a hard thermoset material. Theexterior lighter colored portion of the star is composed of a softthermoset material.

FIG. 5 is a block diagram of an exemplary 3D object production system.In FIG. 5, the slicing application software sends an object descriptionto a controller. The controller sends control instructions to a 3Dprinter to print a 3D object. The 3D printer sends feedback to thecontroller, which then sends feedback to the slicing application. The 3Dprinter contains controllers for monitoring and controlling humidity,temperature, and dry air flow.

Various three-dimensional (3D) object production methods and systems maybe used with the exemplary methods and systems described herein such,e.g., U.S. Provisional Application Ser. No. 62/430,919, filed Dec. 6,2016, U.S. Provisional Application Ser. No. 62/524,214, filed Jun. 23,2017, and PCT Patent Application entitled “MANUFACTURE OF THREEDIMENSIONAL OBJECTS FROM THERMOSETS” and filed on the same day as thepresent application, each of which are incorporated by reference hereinin their entireties.

All patents, patent documents, and references cited herein areincorporated in their entirety as if each were incorporated separately.This disclosure has been provided with reference to illustrativeembodiments and is not meant to be construed in a limiting sense. Asdescribed previously, one skilled in the art will recognize that othervarious illustrative applications may use the techniques as describedherein to take advantage of the beneficial characteristics of theapparatus and methods described herein. Various modifications of theillustrative embodiments, as well as additional embodiments of thedisclosure, will be apparent upon reference to this description.

EXAMPLES

The 3D object production system and methods disclosed herein are nowfurther detailed with reference to the following examples. Theseexamples are provided for the purpose of illustration only and theembodiments described herein should in no way be construed as beinglimited to these example. Rather, the embodiments should be construed toencompass and an all variations which become evidence as a result of theteaching provided herein.

Example 1A

An apparatus capable of dispensing accurate amounts of several reactivecomponents can be used to create 3D objects with a range of physicalproperties.

Process

A 3D Model portraying the filled star (shown in FIG. 4) was createdusing the Solidworks 2018 CAD software and exported as an STL file. Themodel was designed with (1) a raised outline and (2) an inner flat area.

The STL file was processed using an off the shelf “slicing” applicationto create G-Code descriptions of the actions required to create eachindividual area with a unique thermoset material.

Area 1, the outer raised area of the star, was built using Thermoset 1,having a red color and a hardness of Shore 60A. Area 2, the inner filledarea of the star was built using Thermoset 2, having a green color and ahardness of Shora 95A

As shown in Table 1, Thermoset 1 was produced by mixing using tworeactive components, A1 and B1; Thermoset 1 was produced by mixing usingtwo reactive components, A2 and B2:

TABLE 1 Reactive component A1 Reactive component A2 IsocyanateIsocyanate Prepolymer Prepolymer Red tint Yellow tint Starting viscosity5300 cp Starting viscosity 5300 cp Reactive component B1 Reactivecomponent B2 Polyol Polyol Prepolymer Prepolymer 2 Blue Tint Blue TintStarting Viscosity 2660 cp

The ratio of isocyanate:prepolymer was lower for Reactive component A1compared to Reactive component A2. Reactive component B2 had a largerweight percentage of prepolymer as compared to Reactive component B1.

The model was printed in two separate operations using a Hyrel Engine SRprinter with a modified CSD-30 Extruder.

Operation 1

The outer star was printed using Thermoset 1 to produce 6 layers of ageometric pattern defined by the slicing application. Each layer wasdeposited using the following parameters.

Bead height: 0.8 mm

Bead width: 1.2 mm

Linear speed: 25 mm/s

Flowrate: 24 mm³/s

Operation 2

The inner filled star was printed using Thermoset 2 to produce 4 layersof a geometric pattern defined by the slicing application with the sameparameters.

The printed object shown in FIG. 4 demonstrates that (1) each thermosetmaterial is capable of forming a dimensionally accurate representationof the 3D model created by the CAD program, and (2) the two thermosetmaterials bond to form a single object with unique properties, in thiscase color and hardness.

Example 1B

Example 1A was created using a Hyrel extruder that is only capable ofextruding two reactive components at any time. The addition of anextruder capable of combining and extruding multiple reactive componentswill allow:

-   -   1. Areas with unique properties to be extruded simultaneously;        and    -   2. Reactive components to be blended in precise ratios to create        specific properties from reactive components with specific        unique properties.

FIG. 6 shows an extruder capable of combining up to 8 reactivecomponents.

This type of extruder in FIG. 6 would be capable of creating the star ina single operation by selectively extruding reactive components A1 andB1 to create Thermoset 1 while describing the outer raised area of thestar shown in FIG. 1 and extruding reactive components A2 and B2 tocreate Thermoset 2 while describing the inner filled area of the starshown in FIG. 4. Additionally, this type of extruder could create areaswith blended properties by combining Thermosets 1 and 2 in specificratios.

For example, the extruder in FIG. 6 could be used as shown in Table 2:

Thermoset 1 Thermoset 2 Hardness 100% (24 mm³/s)  0% (0.00 mm³/s) Shore60A  50% (12 mm³/s)  50% (12 mm³/s) Shore 75A  0% (0.00 mm³/s) 100% (24mm³/s) Shore 90A

In this way, combining reactive components can generate specificproperties, including hardness, color, optical refractive index, density(foam), and porosity (foam), in precise ratios and can create blendedproperties within defined areas of the model being constructed.

By providing the “slicing” application with a mechanism to understandthe relationship between the mix ratios of each of the reactivecomponents and each specific property, a continuous spectrum ofproperties may be created.

For example, to print the star described in Example 1A in a singleoperation with the hardness of each point within the model beingspecified be achieved by the following steps.

By storing a description of each reactive component A1, A2, B1, and B2within the slicing application and by using those parameters within aproprietary algorithm the slicing application would generate G-Code withdescription of the flowrate used to create a parameter value.

This G-Code description could allow a properly configured 3D objectmanufacturing system to control the flowrate of 4 reactive components tocreate a thermoset material with a hardness blended between Shore 60Aand Shore 90A.

The addition of colored tints in the proper ratio would allow the systemdescribed above to create blended colors. The addition of water in theproper ratio would allow the system described above to generate foamwith a specified density and porosity.

Example 2

Obstructions within the mixing chamber or extrusion nozzle of theextrusion system described in Example 1 can occur for a variety ofreasons. Identification of an obstruction and the initiation ofcorrective actions are a fundamental to the development of a productivesystem for the creation of 3D objects with thermosets.

To identify an obstruction the operating parameters of the extrusionsystem and the reactive component flow must be monitored and comparedagainst normal operating conditions.

FIG. 7 shows an extrusion system similar to that shown in FIG. 6. Bothsystems use several identical ViscoTec 5/5 liquid pumps feeding a mixingchamber with an extrusion nozzle. FIG. 4 uses shows 2 liquid pumps forsimplicity.

Motor Current/Torque

The current drawn by each motor driving a liquid pump can be measured.For a DC motor, the torque required to drive the liquid pump can beproportional to the current drawn by the motor.

Obstructions in the extrusion system lead to the motor driving theliquid pump deliver more torque and therefore cause the motor to draw ahigher current.

In normal operating, the current drawn by the motors driving theViscoTec 5/5 liquid pump range is between 0.5 A and 1.25 A. While peaksabove 1.25 A are possible extended current draws of greater than 1.25 Astrongly suggest the presence of an obstruction.

Reactive Component Pressure

The pressure of a reactive component can be measured using a pressuretransducer.

The pressure of each reactive component can be measured prior to theliquid pump and within the mixing chamber, prior to the extrusionnozzle.

Obstructions can be characterized by an increase in pressure in themixing chamber and are strongly suggested when the pressure in themixing chamber becomes higher than the pressure prior to the liquidpump.

Actual reactive component pressures depend on the viscosity of thecomponent but for a component with a viscosity of 40,000 cp a pressureof 80 psi prior to the liquid pump is typical and while the pressure atthe extrusion nozzle increases to create increased flow the pressure inthe mixing chamber should remain significantly below 60 psi.

Reactive Component Flowrate

The flowrate of a reactive component can be measured using variety ofsensor technologies. The flowrate of each reactive component is measuresprior to the liquid pump and at the outflow of the mixing chamber.

Obstructions can cause either a complete or part reduction of the flowof material. Unfortunately, a lack of material or a pressure failure canalso cause the material flowrate to reduce or stop completely. Bymeasuring both the pressure and material flowrate prior to the liquidpump and at the outflow of the mixing chamber the presence of anobstruction be ascertained. The logic table used to identify thelikelihood of an obstruction is shown in Table 3 below:

TABLE 3 Prior to liquid pump Mixing chamber out flow Flowrate PressureFlowrate Pressure State 1 0.05-6.0 ml/s 80 psi Same as prior to pump0-60 psi Normal 2 0 ml/s 80 psi 0.05-6.0 ml/s 0-60 psi Out of material 30 ml/s 80 psi 0 ml/s 0 psi Out of material 4 0 ml/s  0 psi 0.05-6.0 ml/s0-60 psi Input pressure failure 5 0.05-6.0 ml/s 80 psi Less than priorto pump 0-60 psi Likely obstruction 6 0.05-6.0 ml/s 80 psi Same as priorto pump 60-80 psi Likely obstruction 7 0.05-6.0 ml/s 80 psi Same asprior to pump >80 psi Very likely obstruction 8 0.05-6.0 ml/s 80 psi 0ml/s >80 psi Very likely obstruction 9 0 ml/s 80 psi 0 ml/s >80 psiExtremely likely obstruction

The ViscoTec 5/5 liquid pump can accurately pump liquids at a rate ofbetween 0.05 ml/s and 6.0 ml/s

Reactive Component Mass

In normal operation, the ViscoTec 5/5 extruder is capable of veryaccurately metering the volume of reactive components extruded.

The cumulative volume of material that is intended to be extruded isnoted by the G-Code interpreter running on the 3D printer throughout theproduction of an object.

By adding force sensors to each corner of the build surface the mass ofextruded material can be measured throughout the production of the 3Dobject.

By monitoring the difference between the intended mass of material to beextruded and the actual mass as measured by the force sensors mounted onthe build surface it can be determined if the actual mass of materialdeposited is significantly less than that intended, suggesting apotential obstruction.

The Color of the Combined Reactive Components

By mounting a color sensor such as the AMS AS7261 Tri-stimulus XYZ_NIRSensor in the extrusion nozzle, the color of the combined thermoset canbe measured.

The color of each reactive component can be controlled by the additionof a tint. The color of the final thermoset can be controlled by themixture of the tints present in each component. In Example aboveReactive component A1 contains a red tint, Reactive component A2contains a yellow tint, Reactive component B1 contains a blue tint, andReactive component B2 contains a blue tint.

Combination of any of these components could produce a thermoset with aunique color. Absence or a reduction in the amount of any of thecomponents could result in the extruded thermoset having a measurablydifferent color. Identification of the missing color constituent wouldsuggest a potential obstruction in the extrusion system for thatcomponent.

Spectral Analysis of the Combined Reactive Components

By mounting a multi-spectral imaging sensor such as the AMS AS7265xSmart Spectral Sensor within the extrusion nozzle the chemicalcomposition of the extruded material can be characterized.

By comparing the predicted chemical composition of the extruded materialagainst that measured by the sensor would allow the absence of chemicalconstituents related to a specific reactive component would suggest apotential obstruction in the extrusion system for that component.

Potential Actions

-   -   Initiate a delay and notify the operator    -   Initiate an automated cleaning cycle and notify the operator    -   Initiate an automated purge of the affected material    -   Request that the operator initiate a manual cleaning procedure

Optimization of Obstruction Identification

Historical data for each sensor reading could be collected and storedwithin the 3D printer control system to optimize the identification ofobstructions. For example, the pressure limits for each type of reactivecomponent would be monitored and updated during normal operation toprovide a more accurate understanding of sensor values that wouldsuggest an obstruction.

Example 3

The system described in Example 2 makes use of flowrate sensors to helpidentify obstructions within each component extrusion system. Thosesensors can also be used during normal operation to compensate forinconsistencies in the flowrate caused by variations in the reactivecomponent parameters or tolerances in hardware such as the extrudernozzle.

As can be seen in FIG. 8, small changes in the flowrate of each reactivecomponent can cause non-linear changes to the printed bead height andwidth.

FIG. 8 shows a cross section of three beads printed using a GermanRepRap x400i LAM printer with a ViscoTec Duo extruder. Each bead wasprinted with a thermoset material comprised by 2 reactive components, A1and B1, as shown in Table 4.

TABLE 4 Reactive component A1 Reactive component B1 Isocyanate PolyolPrepolymer Blue tint Red tint Starting viscosity 40,000 cp Startingviscosity 40,000 cp

For the material shown above with an unreacted viscosity of 40,000 cp

100% flowrate (6.0 mm³/s) creates a bead;

-   -   Bead width: 0.9 mm    -   Bead height 0.675 mm

75% flowrate (4.0 mm³/s) creates a bead;

-   -   Bead width: 0.782 mm    -   Bead height 0.645 mm

125% flowrate (8.0 mm³/s) creates a bead;

-   -   Bead width: 1.017 mm    -   Bead height 0.766 mm

Variations in the bead width and particularly the bead height can reducethe quality of the printed object. By monitoring the difference betweenthe desired flowrate and the actual flowrate a Proportional, Derivative,Integral (PID) control algorithm can be employed to to optimize thedesired flow using a control loop feedback mechanism resulting in a moreaccurate and stable flow and a more consistent printed bead.

Example 4

The extrusion nozzle described in the previous examples can in certaincircumstances accumulate parts of reacted thermoset material on the tipof the nozzle. This “blob” of material can interfere with any previouslyprinted material marking the print and potentially mis-align theextrusion nozzle.

The slicing application can identify opportunities to complete anautomated tip cleaning process during the print. The tip cleaningprocess can cause the extruder to move to the edge of the build platformwhere a cleaning wipe can remove any accumulated material from theextrusion nozzle.

The cleaning wipe can be located at the beginning of each print andreplaced after the print is completed.

Example 5

Thermoset materials such as those described can be affected by theenvironmental conditions in which they are contained.

The viscosity, flowrate, and reaction rate of a partly reacted thermosetmaterial can depend on its temperature.

Deposition of thermoset material in a high relative humidity environmentcan cause bubbles in the cured material.

The German RepRap x400i LAM printer is surrounded by a sealed enclosurewith integrated sensor and control systems allowing environmentalconditions to be monitored and controlled.

The enclosure is connected to an air-line providing cool (15° C.) airwith a relative humidity of 0% and kept under positive pressure. Air isintroduced at a rate to maintain a relative humidity of less than 15%within the enclosure. Temperature can be maintained at a constanttemperature between 15° C. and 25° C. Consistent temperature can providebeneficial 3D printing conditions.

Example 6

As described in Example 5, the viscosity, flowrate, and reaction rate ofa thermoset material can depend on temperature.

By monitoring the temperature of the thermoset material, the temperatureof the build surface (build plate) and the temperature of theenvironment within the enclosure described above a number of printingparameters can be optimized for temperature, including;

-   -   a. Time per layer of the thermoset product,    -   b. Flow-rate of the extruded thermoset product, and    -   c. The Viscosity of the extruded thermoset product

Time Per Layer

Each thermoset material has an associated reaction rate. This rate canprovide an indication of the rate at which the material will reach a gelstate. The reaction rate and therefore the time taken to reach a gelstate can depend on temperature. With the reaction rate increasing withtemperature and the time taken to reach a gel state reducing.

FIG. 9 shows an offset pyramid printed with the material described inExample 3. This material reaches a gel state in approximately 90 secondsat 25 C. At this point the material is self-supporting and resists flow.

The offset pyramid print contains approximately 50 layers printed withthe following parameters:

-   -   Bead height: 0.675 mm    -   Bead width: 0.75 mm    -   Linear speed: 12 mm/s    -   Flowrate: 6.075 mm³/s

Each new layer can be extruded onto a previous layer which has reached agel state. As the area of each layer reduces the time required to printeach layer also reduces from approximately 3.5 minutes at the pyramid'sbase to under 10 seconds at the pyramid's peak

Once approximately half the layers have been printed the time taken toprint a layer is less than the time taken to reach a gel state and thesubsequent layer is deposited onto a liquid surface causing the print tobecome unstable.

To create a stable object each layer should have reached a gel statebefore the next layer is deposited. This can be achieved two ways.

-   -   a. The print can pause to allow the prior layer to reach a gel        state.        -   The duration of each pause will be;

Pause Duration=Gel Time−Layer Print Time

-   -   -   For example a layer that takes 30 sec to deposit has a 60            sec delay before the next layer is deposited.

    -   b. The reaction rate of the thermoset material could be        increased by the addition of an additional reactive component.        -   For example, the thermoset described above with a gel time            of 90 seconds at 25 C could have additional catalyst added            using an additional component pump, increasing the materials            reaction rate and reducing its gel time.

Using the temperature data described in Example 5, the printer controlsystem could be optimized to generate a more accurate inter-layer delaybased on a more accurate understanding of the gel time and temperature.For example, shown in Table 5:

TABLE 5 Temperature Gel Time 15° C. 102 s  20° C. 95 s 25° C. 90 s 30°C. 86 s 35° C. 82 s

Viscosity/Flowrate

As has been shown in the previous examples:

-   -   any change in flowrate can cause a change in the height and        width of any extruded bead    -   any change in temperature can causes a change in the viscosity        and flowrate of the extruded material

Using the temperature data described in Example 5, the printer controlsystem could be optimized to correct the desired flowrate for thecurrent temperature of the enclosure, build plate or material.

Example 7

Each object is built within a 3-dimensional space described by threeperpendicular axis, X, Y and Z.

Seam Structure

The seam is the vertical line formed when each layer begins printing atthe same X, Y point. For example, if each layer starts printing from thefollowing coordinates in (X, Y, Z) space a vertical line can becomevisible on the object due to variations in the starting flowrate of theextruded material.

-   -   a. Layer 5—(100.000, 100.00, 4.000)    -   b. Layer 4—(100.000, 100.00, 3.000)    -   c. Layer 3—(100.000, 100.00, 2.000)    -   d. Layer 2—(100.000, 100.00, 1.000)    -   e. Layer 1—(100.000, 100.00, 0.00)

The seam structure can be optimized by moving the starting point ofadjacent layers to random locations within the layer.

Corner Speed

Ideally an extruded bead of thermoset material can be made to changedirection instantaneously. The physical properties of each uniquethermoset material can include its ability to change direction.

As each curve in a 3D printed bead is made up from several linearsegments this ability to change direction can be expresses as a maximumangular velocity where;

${{maximum}\mspace{14mu}{angular}\mspace{14mu}{velocity}\mspace{14mu}\omega} = \frac{d\;\theta}{d\; t}$and  where  θ  is  the  corner  angle andmaximum  linear  velocity  v = ω r where  r  is  the  radius  of  the  corner

FIG. 10 and FIG. 11 show a flattened donut printed with the thermosetmaterial described in Example 3.

The object was printed using the following print parameters:

-   -   a. Bead height: 0.675 mm    -   b. Bead width: 0.75 mm    -   c. Linear speed: 12 mm/s    -   d. Flowrate: 6.075 mm³/s    -   e. Fill pattern: Concentric    -   f. Corner speed: 72 degrees per second

Given a corner speed of 72 degrees per second and a radius of 20 mm thelinear speed would be 12 mm/s.

Optimizing the geometry, resolution and print speed in concert with thethermoset flow-rate can be key to creation of an accurate 3Drepresentation of a 3D model.

1.-64. (canceled)
 65. A three-dimensional (3D) object production systemcomprising: an extruded thermoset printing apparatus comprising: aprinthead comprising a mixing chamber to receive and mix at least afirst reactive component and a second reactive component to provide apartially reacted thermoset product operably coupled to an extrusionnozzle to deliver the partially reacted thermoset product to form a 3Dobject; a metering apparatus to individually control at least an amountand a flow rate of one or more of the reactive components into themixing chamber; and a controller comprising one or more processorsoperably coupled to the extruded thermoset printing apparatus, whereinthe controller is configured to: receive a 3D object design; produce a3D object based on the 3D object design using the partially reactedthermoset product delivered by the extruded thermoset printingapparatus, and adjust one or more printing parameters of producing the3D object based on a reaction rate between the first reactive componentand the second reactive component to provide the partially reactedthermoset product according to the 3D object design, wherein the one ormore printing parameters comprise at least one of: a time per layer ofthermoset product; a flow rate of a proportion of at least one reactivecomponent relative to another reactive component into the mixingchamber, and relative to a volume of the mixing chamber, a flow rate ofthe thermoset product through the extrusion nozzle relative to a volumeof the mixing chamber; a pressure of at least one of the reactivecomponents flowing into the mixing chamber, and wherein the system isconfigured to overlap an end of a first layer with a portion of a secondlayer deposited over the first layer; and/or utilize a different flowrate of the thermoset product through the extrusion nozzle based on across-section of a portion of the 3D object proximate to a start and/orstop point of one or more layers, to reduce and/or hide a seam of the 3Dobject.
 66. The system of claim 65, wherein the overlapping of the endof a first layer with a portion of the second layer deposited over thefirst layer to reduce and/or hide a seam of the 3D object comprisesutilizing a different deposition height of the extrusion nozzle whendepositing the overlapping portion of the second layer.
 67. The systemof claim 65, wherein the utilization of the different flow rate of thethermoset product through the extrusion nozzle based on a cross-sectionof a portion of the object proximate to the start and/or stop point ofone or more layers further comprises avoiding and/or reducing adeposition volume and/or adjusting a deposition height of another layerproximate to the start and/or stop point.
 68. The system according toclaim 65, wherein the one or more of the printing parameters furthercomprise a temperature of the thermoset product, a temperature of aplatform upon which the 3D object is produced, a temperature within acavity of a chamber within which the 3D object is produced, atemperature of the extrusion nozzle, and/or a humidity within the cavityof the chamber within which the 3D object is produced.
 69. The systemaccording to claim 65, wherein the 3D object design comprises an areadefining a geometry, wherein the one or more of the printing parametersare adjusted to form the area based on the defined geometry, and/orwherein the 3D object design comprises an area defining a fill property,wherein the one or more of the printing parameters are adjusted to formthe area based on the defined fill property.
 70. The system according toclaim 65, further comprising: at least one actuator operably coupled tothe printhead to move the extrusion nozzle when delivering the partiallyreacted thermoset product to form the 3D object, and wherein the one ormore of the printing parameters further comprise at least one of: a pathtraversed by the printhead while depositing the partially reactedthermoset product in a layer, a layer pattern; a seam structure; alinear speed traversed by the printhead while depositing the partiallyreacted thermoset product in the layer; and a minimum turning radius fora given linear speed while depositing the thermoset product in thelayer.
 71. The system according to claim 65, wherein the controller isfurther configured to produce the 3D object based on a selected beadwidth, wherein a layer path and a flow rate of the partially reactedthermoset product are based on the selected bead width, and/or a beadwidth is selected for each of a plurality of different areas of the 3Ddesign.
 72. The system according to claim 65, wherein the mixing chamberreceives and mixes at least a first reactive component, a secondreactive component, and a third reactive component to provide thepartially reacted thermoset product.
 73. The system according to claim65, wherein the 3D object design comprises a first area and a secondarea in a different location than the first area, wherein a physicalproperty of the first area is different than the same physical propertyof the second area, and the controller is configured to: generate onemore extruded thermoset printing processes to produce the 3D objectbased on the 3D object design by adjusting one or both of the amount andflow rate of one or more of the reactive components to produce thepartially reacted thermoset product for the first area of the 3D objectdesign, which cures to form the thermoset product comprising thephysical property of the first area that is different than the samephysical property of the second area of the 3D object design.
 74. Thesystems according to claim 73, wherein the physical property isflexibility, color, optical refractive index, harness, porosity, and/ordensity.
 75. The systems according to claim 73, wherein the controlleris further configured to adjust one or both of an amount and a flow rateof the third reactive component comprising a gas-generation source intothe mixing chamber to provide the partially reacted thermoset productfor the first area of the 3D object design to provide the physicalproperty of the first area that is different than the same physicalproperty of the second area.
 76. The systems according to claim 75,wherein the controller is further configured to control a distancebetween the extrusion nozzle and the 3D object based on a foaming ratedetermined by an amount and flow rate of the gas generation source. 77.The system according claim 65, wherein the controller is configured toadjust a flow rate of one or more of the reactive components using themetering apparatus based on one or more flow properties of the partiallyreacted thermoset product produced within the mixing chamber andextruded through the extrusion nozzle.
 78. The system according to claim77, further comprising one or more flow detectors to monitor an actualflow property of each of the reactive components, wherein the one ormore flow properties comprises the flow rate of each reactive componentinto the mixing chamber, and/or one or more pressure detectors tomonitor a pressure of each reactive component prior to entering and/orflowing into the mixing chamber.
 79. The system according to 77, whereinthe controller is configured to calculate one or more flow properties ofthe partially reacted thermoset product to produce the 3D object basedon the 3D object design, and wherein the adjusting of the of one or moreof the reactive components using the metering apparatus based on one ormore of the flow properties of the partially reacted thermoset productcomprises comparing the actual one or more flow properties to the one ormore calculated flow properties.
 80. A method to produce a 3D objectcomprising: providing a three-dimensional (3D) object production systemaccording to claim 65; receiving a 3D object design to be produced intoa 3D object using a thermoset product delivered by the 3D objectproduction system; producing the 3D object based on the 3D objectdesign, by adjusting the one or more printing parameters; wherein an endof a first layer is overlapped with a portion of a second layerdeposited over the first layer; and/or a different flow rate of thethermoset product through the extrusion nozzle based on a cross-sectionof a portion of the 3D object proximate to a start and/or stop point ofone or more layers is utilized to reduce and/or hide a seam of the 3Dobject.
 81. The method of claim 80, wherein the time per layer is fromabout 30 seconds to 30 minutes; and/or wherein the flow rate of thepartially reacted thermosetting material through the extrusion nozzle isfrom about 0.01 mm³/s to 1 mm³/s; and/or wherein the viscosity of thepartially reacted thermosetting material through the extrusion nozzleproduces a bead aspect ratio of the partially reacted thermosettingmaterial from about 1 to about 5, when determined as a cross-sectionalwidth divided by a height of the deposited bead.
 82. The method of claim80, wherein the path traversed by the printhead while depositing thepartially reacted thermoset product in a layer is selected such thatfrom 1 second to 5 minutes elapses before an adjacent bead is placed;and/or wherein the linear speed traversed by the printhead whiledepositing the partially reacted thermoset product in the layer is from1 mm/s to 50 mm/s.
 83. A 3D object produced by the method of claim 80.84. The 3D object of claim 83, comprising one or more seams arrangedbetween layers within the 3D object which are not present on an exteriorsurface of the 3D object.